Material handling apparatus, method and article formed therefrom

ABSTRACT

Material handling apparatus, method and article formed by the method directed to simultaneously dispensing, folding and joining at least two supplies of continuous web material in a predetermined relationship which can be selectively established or vitiated. The apparatus incorporates a folding and guide means for dispensing folded material into a predetermined relationship, additional components to selectively move the folded materials out of and into that relationship and a suitable device for separating the folded materials from the supplies selectively. The method incorporates the steps of folding and dispensing continuous supplies of web material in a particular relationship, selectively sewing together these materials as a part of the sewing operation or otherwise and separating the materials selectively from their supplies.

United States Paten Hester 1 May 23, 1972 [54] MATERIAL HANDLING APPARATUS, 2,821,385 1/1958 Hofi'ee ..112/121127 x METHOD AND ARTICLE F R 2,862,467 12/1958 Passaro 61 al. ..112/12127 x [72] Inventor: James F. Hester, 4 I09 Northampton Drive, Winston-Salem, N.C. 27105 [22] Filed: Mar. 9, 1970 [21] Appl. No.: 17,540

[52] US. Cl ..112/152, 270/41 51 1111. c1. ..D05b 35/06 I [58] Fleldot'Sesu-ch ..112/152,130,121.27,147, 112/136, 102; 2/113, 116; 270/41, 94

[56] References Cited UNITED STATES PATENTS 1,201,423 10/1916 Almond ..112/152 2,823,703 4/1958 Sigoda... ..112/152 X 1,526,933 2/1925 Rhyon.... ..112/152 X 3,515,081 6/1970 Miller... .....1 12/121.27 X 998,956 7/1911 COghill ..112/121.27X

THEREFROM Primary Examiner-H. Hampton Hunter AttorneyCharles Y. Lackey ABSTRACT Material handling apparatus, method and article formed by the method directed to simultaneously dispensing, folding and joining at least two supplies of continuous web material in a predetermined relationship which can be selectively established or vitiated. The apparatus incorporates a folding and guide means for dispensing folded material into a predetermined relationship, additional components'to selectively move the folded materials out of and into that relationship and a suitable device for separating the folded materials from the supplies selectively. The method incorporates the steps of folding and dispensing continuous supplies of web material in a particular relationship, selectively sewing together these materials as a part of the sewing operation or otherwise and separating the materials selectively from their supplies.

1 Claim, 10 Drawing n um PATENTEDMAY 23 I972 SHEET 1 OF 2 INVENTOR JAMES F. HESTER Zflornjy MATERIAL HANDLING APPARATUS, METHOD AND ARTICLE FORMED THEREFROM BACKGROUND OF THE INVENTION on the simultaneously dispensed materials such as perforating,

generally securing or securing in only preselected locations while leaving the materials unsecured in locations other than those desired. Satisfactory automation of such a requirement is extremely difficult particularly when the intermittent operations affecting both materials are of a precise nature to the extent that the operations must begin and end at the same location during each operating cycle.

To illustrate a practical application of the process described above, consider the fabrication of a garment such as the knit shirt commonly used as a mens undergarment or outerwear garment wherein the most functional and aesthetic collar construction of that garment requires a collarette reinforcing member to be superimposed over the exposed rear neck seam formed by the sewing of the collar to the body of the garment. The reinforcing member is sewn directly across the rear neck of the garment to cover the seam and provide a better appearance. Additionally, this reinforcing member controls the stretch of the garment collar by being formed of a different material from the collar or being formed from the same material as the collar except it is applied in a different manner.

The garment of this construction is highly desirable; however, the conventional sewing operation wherein the collarette reinforcing member is superimposed over the rear neck seam is tedious and expensive since the collarette reinforcing member is sewn across the seam after the collar has been sewn to the garment. Because of the expense involved in this garment construction, substitutes have been used to cover the seam including the use of a sewing apparatus producing a twoneedle interlock stitch which floats thread across the seam to partially hide that element.

The present invention has been developed as a result of continuing requirements to dispense and sew selectively two or more supplies of endless material which heretofore has been joined only by securing each individual material separately at those particular locations where securement was desired.

BRIEF SUMMARY OF THE INVENTION The invention relates to material handling apparatus, method and articles formed by using the method which has great application in a variety of areas. To illustrate the parts and operation of the apparatus, the practice of the method and articles formed by the method, reference will be had in the following specifications to the construction of a garment, preferably a knit shirt customarily used by men as an undershirt or an outerwear garment, the design of which completely lends itself to the use of the apparatus and practice of the method disclosed. While the garment design discussed and illustrated herein is an important facet of the present invention, it is representative only of an embodiment wherein the apparatus and method have extremely useful application, and there is no intent to limit the invention to the garment described herein.

The material handling apparatus set forth includes two fold ing and guide devices which dispense folded web material along a predetermined path of travel. Means are provided for selectively displacing the folding and guide devices withl respect to each other so that the folded and dispensed materials are moved into and out of a predetermined relationship each with the other. The apparatus is provided with means for securing the dispensed and folded material in a predetermined relationship and also contains means for severing folded materials from the material supplies. The folding and guide devices are preferably of a V-shaped design which continuously folds the web material substantially along the middle while placing the folded web at a preselected location particularly with respect to the other folding web being dispensed simultaneously therewith.

The method of dispensing endless lengths of material simultaneously and securing these materials selectively each to the other in a predetermined relationship after which the material is separated from the supply normally by a conventional overedge seaming and cutting machine such as the Union Special 39500, is particularly well suited, as has been previously mentioned, to the construction of an article of wearing apparel wherein the collar construction requires two folded pieces 'of fabric to be sewn to the garment, one of the fabric pieces being superimposed over the other. While it will be appreciated that the novel method has unique application in the construction of this garment, it is in no way limited to the garment construction disclosed but may be used in any application where simultaneous application of endless material and selective securement each with the other is required.

From the foregoing background and brief description, it will be apparent that a primary objective of the present invention is to provide a material handling apparatus for simultaneously folding and dispensing at least two materials from an endless supply one of which may be selectively displaced with respect to the other during the folding and dispensing operation.

Another primary objective of the present invention is to provide a method for simultaneously dispensing and selectively attaching one or more materials from an endless supply in a predetermined relationship. Another important objective of the invention is to disclose an application for the use of the apparatus and method previously referred to which will illustrate the importance of the invention in a practical setting. In the embodiment illustrated, it is a further objective to illustrate and describe the construction of a garment utilizing the princi-- ples set forth above.

The objectives mentioned above and other equally important objectives will become more apparent after a consideration of the following detailed description taken in conjunction with theaccompanying drawings wherein like characters of reference designate like parts throughout the several views.

FIGURE DESCRIPTION FIG. 3 is an end elevational, fragmentary, sectional and schematic view of the folding and guide members illustrated in FIG. 2 showing the displaceability of one of the members by means of a pneumatic cylinder with respect to the other.

FIG. 4 a through 4 e is a sequential portrayal of a garment the collar of which is constructed using the apparatus and method disclosed herein.

FIG. 5 a is a sectional view taken along the lines 5 a 5 a showing the garment collar and collarette reinforcing member after these components have been attached to the body of the garment.

FIG. 5 b is a sectional view taken across lines 5 b 5 b illustrating the collar and the collarette reinforcing member which has been turned down and secured directly to the body of the garment to hide the scam in the neck portion.

DETAILED DESCRIPTION OF THE DISCLOSURE To illustrate the apparatus and method disclosed herein, the structural components will be'described and discussed in association with a conventional sewing machine and used in the construction of a garment such as illustrated in FIGS. 4 a through 4 e. The sewing machine shown generally as 10 is of a conventional construction and suitably designed to simultaneously cut and sew fabric and to accomodate materials forming the elements of the garment referenced above. Two supplies l2 and 14 of web material feed continuously downwardly (see arrows) into material folding and guide devices generally indicated as 16 and. 18 and illustrated particularly in FIG. 2. Device 16 has a substantially flat adjustable upper portion 20 for receiving web material of various thicknesses and has a sleeve 22 below into which the web material is extended and from which the folding operation commences. The web material moving through devices 16 and 18 is fed by the feeding mechanism under the presser foot of the sewing machine so that material is being drawn through the devices so long as the machine is in operation and the folded materials are positioned under the presser foot (not shown) of the machine.

Commencing with upper portion 22 of device 16, there is an inward taper in width experienced as the device extends downwardly while an increase in depth occurs so that a V shaped material folder 24 results. A portion 26 of the lower end of the device 16 extends downwardly to form a fabric guide and has a horizontal foot flap 28 beneath from which the folded web material emerges.

Device 18 is similarly constructed at least to the extent that a V-shaped folder 30 is formed from which extends downwardly side walls 32 and between which passes the folded web material until it emerges from an encircled enclosure 34 at the bottom of the walls 32. Thus both devices 16 and 18 are capable of simultaneously dispensing continuous web materials in the manner subsequently to be described.

Since the usual requirement is for the superimposition of one web material over the other for a selected time, location or area, it is necessary that means he provided for engaging and disengaging device 18 to the extent that the web material dispensed therefrom can be superimposed over the web material dispensed from device 16 as planned or desired. To accomplish this operation, device 18 is movably supported on a carriage 36 that is slideably displaced by a positioning means, in this instance shown as a pneumatic valve and generally indicated as 38. Air lines 40 and 42 extend to an air source (not shown) which is controlled by an actuating mechanism 44 operable by the knee of the machine operator. Device 18 is displaceable between limits as shown in FIG. 3 from the solid outline of the device to the phantom outline positioned to the left. The carriage 36 is suitably supported in any convenient manner to provide for this displacement between limits.

The switching mechanism of device 44 is such that actuation of the device by the operator will displace device 18 in one direction until the physical limit of displacement is reached. Device 18 will remain in that position until the actuating mechanism 44 is again operated by the operator at which time the opposite air line will be charged and the device 18 will be returned to its original position awaiting in that position the next operation of mechanism 44.

It can be seen from FIG. 2 that whenever the mechanism 44 is actuated and the device 18 is displaced in close proximity with device 16 so that its continuous web of material is superimposed over the continuous web of device 16, the presser foot of the sewing machine will automatically engage this fabric and move it in unison with the fabric extending from device 16 while sewing both foldedmembers simultaneously. Because of this inward and outward selective movement when the device 18 is actuated, a slight taper 39 in the collarette reinforcing member is experienced since the displacement of the device 18 into the sewing path will be such that stitching starts at the instant the edge 40 of the material extending from device 18 engages the sewing machine needle and continues until the material is fully extended to the desired location with respect to the material extending from device 16. This tapering action takes place when the device is withdrawn from engagement so that a unifonn and symmentrical collarette reinforcing member is attached to the collar.

The garment formed by the use of the apparatus and method disclosed herein is shown at various states of construetion in FIGS. 4 a through 4 0 wherein FIG. 4 a is the garment with its body portion 45 and two sleeves 46 joined together and forming an opening 48 for the neck. FIG. 4 b shows the garment after the neck bancl 50 represented by the material 16 folded and fed from device 16 and the collarette reinforcing member 52 represented by the material 18 folded and fed from device 18 are nearly completely attached to the body of the garment. FIG. 4 c illustrates the final garment wherein the collarette reinforcing member successfully hides the un desirably seam (shown in phantom line as 54) in the rear portion of the neck of the garment and offers additional stability to the neck to prevent stretching. This is successfully accomplished by forming the collar of knit material which is cut across the wales of the knitted fabric and forming the collarette reinforcing member of knit material which is cut with the wales of the knitted fabric. Cutting the material across the wales gives the collar quite a bit of stretch because of the basic construction of the knitted fabric. However, the knitted fabric is highly stretchable only in one direction; consequently, when the collarette reinforcing member is cut with the wales, very little stretch is experienced in that element, thus providing a stretch control feature when positioned in the neck of the garment as shown in FIG. 4 c.

FIG. 5 a illustrates a sectional view taken along the lines 5 a 5 a of FIG. 4 e after the sewing operation attaching the collar and collarette reinforcing member to the body of the garment has been completed. Note that the collarette reinforcing member is turned slightly upwardly. It is generally desirable to subject the garment to a second sewing operation so that the collar arrangement is as sectionally shown in FIG. 5 b; however, this second sewing operation is not absolutely necessary since the collarette reinforcing member could be turned downwardly over the seam to substantially cover that element as desired by ironing or adhering the collarette member to the body of the garment in some other equally suitable manner.

While manual means 44 for selectively engaging and disengaging device 18 is described in the embodiment disclosed herein, it will be readily apparent that an automatic operation can be incorporated by using a stitch counting mechanism attached to the sewing machine whereby device 18 is engaged after so many stitches have occurred and disengaged after completion of an additional selected number of stitches. Other suitable devices for effecting automatic operation and relieving the operator of this responsibility include the positioning of a microswitch to sense the location where the collarette reinforcing member is to be introduced and again sensing the location where this member is to be terminated. Suitable markers or stitches can be incorporated in the body of the garment to provide triggering means for the microswitch.

Applications for the present invention lie in many fields other than the textile art discussed and disclosed in the embodiment illustrated herein. Many different embodiments would readily occur to those skilled in other areas of technology where the simultaneous and selective dispensing and positioning of web material in a predetermined relationship, it is to be understood that the specific embodiment presented herein is not to be construed as limiting. Limitations are to be determined only from the appended claims.

lclaim:

1. Material handling apparatus comprising: first and second material supplies; first folding and guide means dispensing folded material from said first material supply along a predetermined path of travel; second movable folding and guide means dispensing folded material from said second material supply in a predetermined relationship with said first dispensed folding material; means selectively positioning said second movable folding and guide means to move said folded and dispensed material into and out of a predetermined relationship withthe dispensed material from said first folding and guide means; means securing said dispensed and folded materials in a predetermined relationship each with the other;

preselected location, said positioning means selectively displacing said second V-shaped material folder horizontally into and out of a predetermined registered relationship with said first V-shaped material folder, said securing means including a sewing machine joining said first and second folded webs to another independent and separate material. 

1. Material handling apparatus comprising: first and second material supplies; first folding and guide means dispensing folded material from said first material supply along a predetermined path of travel; second movable folding and guide means dispensing folded material from said second material supply in a predetermined relationship with said first dispensed folding material; means selectively positioning said second movable folding and guide means to move said folded and dispensed material into and out of a predetermined relationship with the dispensed material from said first folding and guide means; means securing said dispensed and folded materials in a predetermined relationship each with the other; and means collectively severing each of said folded materials from said material supplies at predetermined times, said first folding and guide means including a V-shaped material folder folding a web of material substantially along the middle and placing said folded web at a selected location, said second folding and guide means including a second V-shaped material folder folding a second web of continuous material substantially along the middle and placing the second folded web at a preselected location, said positioning means selectively displacing said second V-shaped material folder horizontally into and out of a predetermined registered relationship with said first V-shaped material folder, said securing means including a sewing machine joining said first and second folded webs to another independent and separate material. 